Reinforced hollow plastic pipe



United States Patent Inventors Henry M. Richardson,

Somers;

Alfred C. Alberghini, Hazardville, Conn.;

Fred E. Wiley, Longmeadow, Mass;

g Wesley S. Larson, Hazardville, Conn.

Appl. No? 833,867

Filed June 3, 1969 Continuation of Ser. No. 627,519, Mar. 31, 1967, which is a division of Ser. No. 486,678, Sept. 13, 1965, now Pat. No. 3,377,657, which is a division of Ser. No. 248,058, Dec. 28, 1962, now Pat. No. 3,256,128, dated June 14, 1966 Patented Sept; 2, 1 976 Assignee The Youngstown Sheet and Tube Company,

Boardman, Ohio, a corporation of Ohio REINFORCED HOLLOW PLASTIC PIPE 5 Claims, 31 Drawing Figs.

US. Cl 138/144, 156/162, 242/723 Int. Cl F161 9/16 [50] Field ofSearcli 242/702, 7.21, 7.22, 7.23 lnq; 156/161, 162 lnq; 161/47 lnq;l38/l22,l29, 131,132, 141,144,145

[56] References Cited UNITED STATES PATENTS 3,128,216 4/1964 Reed 24217.22X 3,190,780 6/1965 McNulty et al. 242/7.22X

Primary ExaminerHouston S. Bell, Jr.

ABSTRACT: This patent discloses a mold for plastic pipe having two elongate semicircular members which embrace the exterior of a preform to be cured. The members are held within an encircling body which provides heat for curing. An internal bladder expands the preform against the two semicircular members. Gases from the preform escape through the juncture of the semicircular members and out through the encircling body. The resulting pipe has all of its reinforcing strands under substantially equal tension. For a disclosure of the entire method and apparatus employed in fabricating the pipe, see U.S. Pat. No. 3,256,128 which is incorporated herein by reference.

Patented Sept. 29, 1970 Sheet 1 of 16 Q 3 rnfi Rm 2m 3% W e y q Q m 0 JE 5H T. t W Em NE Ma 0 mum F ms 8% New w m 3m E muN mvm Al Nmm mow Hm b plldllL l an mu uum 09m mmwhm E. W/LEY FRED 00w mwqum WESLEY 5.

vPatented 29,- 19 70 Sheet 2 of 16 Ill , A f'm-vENToRs HENRY 'M E/cHneosoN flLFesa c. RL EEGH/M/ FEED E. SW/LEY WESLEY Lnes qu QTTY Patented Sept. 29, 1970 Sheet INVENTORS HENPY, P/cH I HPOSON flLaEEGH N W/AEV N Patented Sept. 29, 1970 Sheet 4 of 16' H M IPINVENTODRON EN 'ICHHQ Q iifi WESLEY S, LIQESON RTTY Patented Sept. 29, 1970 Sheet I 0 MIN wk wk V mq wk HENRY M. P/

Patented Sept. 29, 1970 Sheet INVENTORS Q/CHHRDSON m BERGH/N/ HENRY E.

QLFEED FRED W/LEY L-HERSON WESLE Patented Sept. 29, 1970 Sheet 11 of 1 "3 FEED w/LEY WESLEY 5 ILHQSOIV QTTY Patented Sept. 29, 1970 Sheet I?) of 16 Patented Sept. 29, 1970 Sheet 14 of16 WESLEY 5, 1.4250

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REINFORCED HOLLOW PLASTIC PIPE This is a continuation application of our copending application Ser. No. 627,519, filed Mar. BL 1967, which was a divisional application of our copending application Ser. No. 486,678, filed Sept. I3, 1965, now U.S. Pat. No. 3,377,657, granted Apr. 16, 1968, which was a divisional application of our application Ser. No. 248,058, filed Dec. 28, 1962, now U.S. Pat. No. 3,256,128, granted June 14, 1966.

This invention is a method and apparatus for making a reinforced hollow plastic article and, while adapted for the fabrication of articles of different kinds and for different uses, is of outstanding utility in the manufacture of pipe formed from wrapped strips and/or tapes of fibrous material in which tapes are incorporated reinforcing glass strands which extend parallel to one another and to the lateral edges of the tapes.

The primary objects of this invention are to produce a nonmetallic pipe having an impervious, corrosion-resistant plastic lining encased within resin impregnated fibrous tapes having longitudinal reinforcing strands, with right and left hand wrappings of reinforced tapes under balanced condition and to provide such a pipe by including, in its manufacture, molding and curing steps which stretch or tensilize each layer of the wrappings in turn, so that all of said reinforcing strands are brought to the same degree of tension, with the result that, when internal fluid pressure is applied to the pipe in use, stresses thereon are carried by all reinforcing strands equally.

In carrying out this invention, a mandrel, composed of successive sections, detachably joined end to end, is caused to travel along a predetermined path. As it so travels, there is first applied to the mandrel a helically wound liner. This liner is applied to the mandrel at a first winding station embodying two winding heads arranged to rotate about the mandrel and to supply to the latter a liner consisting of two plies of a suitable corrosion-resistant material, such as unplasticized polyvinyl chloride strips helically wound in the same direction with one ply overlying the other and with the edges of each ply abutting one another, in such manner as to break joints with the abutting edges of the underlying layer.

The first ply of the liner applied to the mandrel has been previously coated on the outside, to contact the second ply, with a thin film of a combination of a phenol resin and an acrylonitrile-butadiene synthetic rubber (Buna-N). This layer of adhesive is previously laid down from an ethyl acetate solution. The solvent is then dried and the adhesive left on the polyvinyl chloride strip surface in such condition that it is substantially nontacky, but will adhere to itself under pressure.

The second layer of liner strip of the same kind, wound on the mandrel, has a coating of vinyl resin polymer adhesive on its surface which engages with the first layer of vinyl strip. The function of the adhesive film is two-fold. Its first function is to act as a pressure sensitive adhesive to hold the two layers of polyvinyl chloride strip in the preform until the latter is subsequently molded, as hereinafter described. Also, during the molding operation, the preform is internally expanded and the adhesive cured and thermoset to form a tenacious bond between the liner layers.

After the liner has been applied to the mandrel as stated, there is next applied over said liner, at successive stations, a plurality of layers or plies of resin impregnated, highly absorbent paper, such as kraft, or asbestos, carrying on its surface parallel laid reinforcing fibers, preferably of glass. This overlay consists of a fibrous web of paper or asbestos fibers in strip form and impregnated with a solution of a curing, thermosetting resin, e.g., phenolic or epoxy resin, combined directly with parallel laid glass fiber strands in the form of a sheet or "beam". In practice this beam may consist of from 60 to l20 glass strands per inch of width. The combined strip, comprising the fibrous web with the glass strands laid on it, is then passed through a drying oven and is conditioned to have the proper flow and cure characteristics to produce the end product cured plastic pipe. The reinforced web is then slit to a width such that when it is helically wound on a mandrel with a helix angle, which is determined by the desired distribution of circumferential and longitudinal elongation characteristics of the finished pipe, will wind without overlap and without leaving a gap. Therefore, each individual helical wrap forms a continuous tubular element ply in the wall of the pipe.

The fibrous web to which reference has been made may, if desired, embody asbestos fibers prepared in accordance with the disclosure of U.S. Pat. No. 2,626,213 granted January 20, 1943 to L]. Novak, used according to said disclosure or in combination with randomly oriented glass or other fibers.

The process of making the pipe from this prepared and slit tape is one of continuous winding on mandrel sections which are successively detachably coupled to one another and fed in continuous succession through the continuous wrapping machine of this invention. The assembled mandrel sections may be of any desired length, e.g. 20 ft., and they may be of any desired diameter. They are successively coupled together end-to-end and are fed to and through the machine by a pushing or feeding unit which propels them through several winding stations during the wrapping operations to which reference has been made. At these successive stations, progressive winding strands are constituted to alternatelyfeed the glass reinforced tapes in opposite directions or hand and automatic mechanism is provided to maintain each of the tapes at all times under uniform tension so that, even in the finished preform, the tension on all of the tapes is uniform and balanced.

After the preform has been completed on any particular section of mandrel, this preform is severed at a mandrel coupling by rotating knives and said preform, with the mandrel section therein, is moved free from the following mandrels and windings and discharged from the machine. The mandrel section contained in such preform is then removed from the preform and the latter is subjected to a molding, tensioning and curing operation in the presence of sufficient heat to thoroughly cure the resins therein contained and produce a homogeneous construction, with the reinforcing glass fibers of the several layers or plies under a tensilized balanced condition. Maximum circumferential and longitudinal strength of the pipe results. In such a pipe, the pressure of fluids passing through such pipe will be borne equally by all plies or layers of the pipe.

In addition to the foregoing steps of this process, provision may be made for the coupling together of successive lengths of pipe sections to form a continuous conduit in the field or plant where they are installed for use.

Features of this invention, other than those adverted to, will be apparent from the hereinafter detailed description and appended claims, when read in conjunction with the accompanying drawings.

The accompanying drawings illustrate one practical embodiment of the invention, but the construction therein shown is to be understood as illustrative only, and not as defining the limits of the invention.

FIGS. 1 and 1A collectively constitute a pictorial side elevation of apparatus embodying the present invention.

FIG. 2 is an exploded perspective view, partly in section, of coupling elements used to secure in axial alinement successive mandrel sections on which the pipe is formed.

FIG. 3 shows said coupling elements in assembled relation, partly in central section and partly in elevation.

FIG. 4 is a section on the line 4-4 of FIG. 3.

FIG. 5 is a diagrammatic showing of the main drive mechanism of the structure shown in FIGS. 1 and 1A.

FIG. 6 is a perspective view showing the mechanism for advancing assembled successive mandrel sections through the greater portion of the length of the machine.

FIG. 7 is a transverse section on the line 7-7 of FIG. 6, showing means for gripping and feeding the assembled mandrel sections in succession as they pass into and through the machine.

FIG. 8 is a perspective view of the parts shown in FIG. 7.

FIG. 9 is a perspective view of one of the winding stands, the duplication of certain parts thereof being omitted in the interest of clearness.

FIG. is a plan view of one of said winding stands with certain parts omitted.

FIG. 11 is a vertical section on the line 11-11 of FIG. 10.

FIG. 12 is a fragmental elevation looking in the direction of the arrow 12 in FIG. 10.

FIG. 13 illustrates a rheostat employed to control the tension of the tapes as they are wound on the mandrel.

FIG. 14 is a graph illustrating the characteristics of the rheostat of FIG. 13 during the functioning thereof.

FIG. 15 is a wiring diagram of the tape tensioning aspect of this invention.

FIG. 16 is an exploded view of cut-off mechanism whereby successive lengths of the formed pipe are cut from the following portions to produce a preform after a pipe section has been fully wound and while it continues to travel.

FIG. 16A shows one of the cutter and cam arms of the assembly shown in FIG. 16.

FIG. 17 is a wiring diagram for the cut-off mechanism shown in FIG. 16.

FIG. 18 is a fragmental perspective showing mechanism for separating a preformed section of pipe, with mandrel section therein, from the following pipe and mandrel sections after such preformed pipe has been severed by the mechanism shown in FIG. 16. This view also shows mechanism for discharging the preform and the enclosed mandrel section from the machine.

FIG. 19 is a detailed view showing the operation of the pulling jaws shown in FIG. 18.

FIG. 20 is a side elevation of mechanism for supporting and registering the mandrel and partially wrapped pipe thereon with each successive winding stand of the machine as they leave the preceding stand.

FIG. 21 is a section on the line 21-21 ofFIG. 20.

FIG. 22 is a section on the line 22-22 of FIG. 20.

FIG. 23 is a longitudinal view, partly in section and partly in elevation, showing the manner of removing a coupling part from one end ofa mandrel section.

FIG. 24 is a like view showing the manner of removing a mandrel section from a preformed pipe previously formed thereon, to ready the preform for the final molding and curing operations.

FIG. 25 is a cross section on the line 25-25 of FIG. 24.

FIG. 26 is a longitudinal section of one end portion of the molding and curing elements for the preformed pipe.

FIG. 27 is a cross section on the line 27-27 of FIG. 26.

FIG. 28 is a cross section of the line 28-28 of FIG. 26.

FIG. 29 is a side elevation of the mold as it appears when ready'to carry out its functions.

The several successive mechanisms or stages for producing the preformed pipe of this invention are bracketed in FIGS. 1 and 1A of the drawings and respectively designated 100. 200," 300, and 400. They will be hereinafter individually described in this order.

Prior to the feed of the mandrel sections M to the mechanism of Stage 100, they are detachably secured end to end by a novel form of coupling shown in FIGS. 2, 3 and 4. Each of these couplings embodies two parts, namely, a male part 1 and a female part 2. To accommodate this coupling the opposite ends of each of the mandrel sections are interiorly machined to a true cylindrical end portion coaxial with the exterior surface of the section and across the hollow interior of this machined portion extends a pin 3.

The male part I is, in the main, cylindrical, but one end has a reduced shank 4 to provide what may be referred to as a clothespin projection having a reentrant mouth 5 at the base of which is formed an angularly disposed hole 6. When this clothespin projection is introduced into the adjacent end of a mandrel section and given a slight rotary turn, the pin 3 will move into the hole 6 and thus lock the male part to that end of the mandrel section after the manner of a bayonet joint, as seen in FIG. 4. In order to insure concentricity between the mandrel and the main portion of the male part, said male part is provided at the base of the clothespin projection with a land 7 of the same external the pin 3 will move into the hole 6 and thus lock the male part to that end of the mandrel section after the manner of a bayonet joint, as seen in FIG. 4. In order to insure concentricity between the mandrel and the main portion of the male part, said male part is provided at the base of the clothespin projection with a land 7 of the same external diameter as the machined internal diameter of the mandrel section M. The distant end of the female part 2 is formed with a clothespin projection 4 and hole 6 corresponding to the like portions of the male part and adapted to engage with the pin 3 of its adjacent mandrel section M.

The contiguous ends of the two coupling parts 1 and 2 are respectively provided with a slip connection embodying a lug or tang 8 and a socket 9 to receive said lug in fairly close fitting relation. The lug 8 is shown as square, although it may be of any polygonal cross section. Said lug 8 may, if desired, be provided therein with a hole 10 containing a spring pressed ball detent. The walls of the socket may also be formed with alined holes 11 to detachably receive the ball. The tang and base of the socket both have coaxially tapped holes 12, which are useful as hereinafter described in the withdrawal of the coupling parts from the preform prior to withdrawal of the mandrel.

An important feature of this invention resides in the provision on the coupling of a relatively soft external surface. This is preferably accomplished by reducing the adjacent end portions of the parts 1 and 2 as shown at 13 and fitting tightly upon these reduced portions sleeves 14 of some relatively soft material against which cutting rolls may act in cutting a completed preform from the preceding windings after each preform has been completed.

As hereinafter described, this cutting of the preform is initiated by a sensing device (e.g. Westinghouse proximity limit switch). the operation of which is controlled by the effect of different materials upon an inductive field. In order to so function, such a difference is dependent upon the passage of a magnetic or nonmagnetic part in proximity to the sensing device. If the mandrel sections have magnetic characteristics, the parts I and 2 of the coupling have nonmagnetic characteristics and the sleeves 14 must also have nonmagnetic characteristics. In practice it is preferred to make the mandrel of steel, the main parts of the coupling of aluminum, and the sleeves 14 of a nonmagnetic resin, such, for example, as polyethylene. With this relation between the parts, the sensing device is so constituted that it will react when the couplings pass in proximity thereto to actuate the severing mechanism as hereinafter described in detail.

As the mandrel sections are successively coupled together as stated, they are fed as a complete mandrel to the machine shown in FIGS. 1 and 1A. It is essential that the sections be close-coupled for, if any tang 8 is not fully seated in its cooperating socket 9, a void will be left between the contiguous ends of the parts of that coupling. This would cause difficulty during the passage of the mandrel through the machine. Consequently a feeler finger 101 (FIGS. 1 and 6) is positioned to bear against the mandrel as it is fed. If this finger feels any void in the mandrel, it operates a switch to stop the machine.

STAGE 100. FIGS. 6, 7 and 8.

The function of this stage is to grip the mandrel fed thereto and push it through the stages of the machine up to the point where a finished preform is cut from the following windings. To accomplish this function, there is provided in this stage a series of mandrel engaging clamps 102.

Each of these clamps 102 is mounted on a carrier 103 which is in turn secured to an endless chain 104. This chain passes around directional sprockets 105 and is driven by a drive sprocket 106 which is supported on a shaft l07journalled in side rails 108 of this unit of the machine. The sprocket shaft 107 is driven through a sprocket 109 and chain connection 110 (FIG. 5) form a right angle gear reducer 15 which is in turn driven from a gear box 17, belt driven from the adjustable speed motor 16 which constitutes the prime mover for the machine.

Each clamp 102 embodies two arcuate clamping jaws mounted for opening and closing movement on a pin 111 (FIGS. 7 and 8) which supports the jaws on its carrier 103. The opposite sides of the carrier extend downwardly and mount guide wheels 112 (FIG. 7) which ride on lower tracks 113 carried by the side rails 108. Above these lower tracks 1 13 are upper tracks 114, the lower edges of which form with the lower tracks 113 longitudinal runways 115 (FIG. 8) in which the wheels 112 travel to keep the clamp from tilting, whereby the clamps 102, when closed, travel coaxially with the mandrel.

Mounted totravel on each of the upper guides 114 is a wheel 116, which is mounted upon one end of a toggle arm 117, the other end of which is secured to a toggle link 118 by a pivot pin 119. The distant end of each toggle link is pivotally secured in a slot 120 to a lug 121 rigid with one jaw of the clamp. An adjusting screw 122 acts upon the upper pivot pin of the toggle link 118 to adjust the throw of the toggle and the pressure exerted by the jaws on the mandrel. Springs 123 normally break the toggle from the stressed position which it assumes when the corresponding jaw of the clamp is in closed position. The toggle arrangement described is duplicated on both sides of the carrier, the toggle arm 117 in each case being supported on a pivot pin 124. When the toggles are in the stressed position shown in FIG. 7, the jaws are firmly closed upon the mandrel at the point where the latter passes through each clamp.

In order to insure a firm grip upon the mandrel and insure positive pushing action by the several clamps, the jaws of each clamp are preferably provided with a cast iron liner 125. With the gripping action produced by such a liner, there is no slippage between the several clamps and the mandrel. In practice, the inner radius of each jaw is slightly different than the outer radius of the mandrel so that deflections resulting from the toggle action will assure accurate mating friction surfaces between said jaws and the mandrel.

The operation of the machine of this invention has demonstrated that special means must be provided for bringing the clamps in succession into cooperation with the mandrel, otherwise there is a probability that the clamp sections, when brought into position to engage the mandrel, will strike the same and throw the mandrel out of line. This will cause trouble in the subsequent operations of the machine. This difficul-- ty has been overcome by the particular formation of the wheel supporting surfaces of the lower and upper tracks 113 and 114. The lower track may be flat throughout so that, as the chain advances each clamp carrier 103, the wheels 112 of such carrier will first be raised to the level of track 113 and proceed to travel along the same.

It is essential as a protective measure against damage to the parts that the clamps be fully opened as they approach engagement with the mandrel. In order to insure this, there is mounted at the forward end of the machine camming members 116a (FIG. 6) so placed that, as the carrier 103 passes from the lower path of its travel to the upper path thereof, these camming members 116a will lie in the path of the toggle wheels 116 of any clamp which may be closed at that time. The engagement of the wheels 116 with these camming members 116a will open such a clamp and prepare it to properly cooperate with the mandrel.

Moreover, the clamp on each carrier must not be closed until the mandrel has entered the confines of the clamp. To insure this, the left hand or leading end of each upper track has (FIG. 8) an abrupt sloping portion 126 merging into a portion 127 of less slope which, in turn, merges into the flat surface of the upper track 114.

Simultaneously with these operations, the toggles, which approach the tracks 114 in broken, i.e., open position, first engage their wheels 116 with the abrupt inclination 126 of the upper track to partially close the gripping jaws, while the less sloping portion 127 of the upper track completes the closing of the jaws as the axis of the clamp comes into substantial registration with the axis of the mandrel. Meanwhile the upper reach of chain 104 is supported on slide 131 (FIG. 7). Ex-

perience with this construction has shown it to be throughly reliable for it insures proper gripping of the mandrel without any tendency to throw the latter out of line.

As the toggle wheels 116 ride up over the inclined portions 126 and 127 in succession, they will move the toggle arms in directions to close the clamping jaws upon the mandrel and these jaws will be finally closed by the time these toggle wheels 1 16 arrive at the flat horizontal portions of the upper surfaces of the upper tracks 114.

This relation between the parts persists while each clamp travels along said upper horizontal surface of the upper track 114, to push the mandrel forwardly until the toggle wheels 116 come to the opposite ends of both tracks. These opposite ends are shown in FIG. 8. Each upper track is there stepped down, as shown at 128, and into these stepped-down portions, the wheels descend, assisted in such descent by knock-down pins 129. The descent of these wheels is sufiicient to throw the toggles over dead centers, i.e. break the toggles, at which time the springs 123 will cause the toggles to be fully broken to open the jaws of the associated clamp.

By continued movement of the carrier, the wheels 116 will leave the tracks, to be carried by the chain 104 in a retrograde direction at a lower level to the point of starting. During this return movement, the wheels 112 will be guided to starting position by lower guides 130 (FIG. 7) which will preclude undue sagging of the chain. Also during return movement, the springs 123 will hold the toggles in broken condition and the clamps open until the operations described with respect to engagement of the clamps with the mandrel are repeated.

STAGE 200. FIGS. 9-15 As the mandrel is pushed along a rectilinear path by the clamps 102, it passes through a plurality of winding stands which may be of any desired number, depending upon the wall thickness and consequent strength of the desired end product pipe. During its passage through the first stand, there is applied to the mandrel a pipe liner, comprising at least one ply of, e.g., unplasticized polyvinyl chloride. As it passes through succeeding winding stands, there is applied over this pipe liner successive layers or plies of the preferably glass fiber reinforcing tapes of the character hereinbefore described.

FIGS. 912 of the drawings show one of these stands, the others being of identical form except that the several consecutive stands are so constituted as to wrap the glass reinforced tape in alternate directions or hands, i.e., with right and left hand helices, respectively. In the stands which wrap the glass reinforced tapes, provision is made for the taking up of an interleaf of any suitable character which is positioned between the successive convolutions of the coiled strips of such tapes. The purpose of this interleaf is to preclude successive convolutions of the tape from sticking to one another in such manner as to interfere with the proper feed of the tape to the mandrel. In the stand which feeds the unplasticized polyvinyl chloride strips, an interliner is also used where these strips have an adhesive backing.

As shown generally in FIG. 9, each stand comprises a pair of spaced apart upright frames 201 and 202. Journaled for rotation in bearings on the frame 201 is a sprocket 203 and similarly journaled for rotation at the inner side of the frame 202 is a plate 204. The sprocket and plate are rigidly secured in spaced relation by spacer bars 205 and 206 which, together with the sprocket and plate, form a rotatable winding head.

Mounted on one side of the spacer bar 205 is a pivot block 207 carrying a pivoted arm 208 which serves as a support for a roll 209 of liner strip or reinforced glass tape T, as the case may be. It is from this coil that the liner strip or tape is fed to the mandrel as the winding head rotates about the latter in such a manner as to lay the strip or tape on the mandrel in a helical path with the strip or tape from that particular roll in edge abutting relation to form one layer or ply thereof on the mandrel. The pivot block 207 is mounted for adjustment longitudinally on the bar 205 so as to obtain proper correlation of the edge abutting joints of the successive layers of strips and tapes. 

